Homemade intake

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Homemade intake

Postby Cschafer » Wed Jan 10, 2007 4:40 pm

I'm not sure how much these tube intakes cost but I'm bettin this is cheaper. Go to the parts store or truck shop and get two pieses of 4in exhaust pipe with 45 deg bends as tight of a radius as possible. Cut the first one down to the point were it will leave your turbo and clear the alternator. Clamp your BHAF or other to the end of the second 45 and hold it up to the first. Fit and trim untill it sits on the fender good and lines up with the first 45. Mark it and weld it up. Get some sort of 4in rubber hose to hook it to the turbo with two clamps and your done. Grind it down and paint it all up and you have a good looking setup for less than 100 bucks with a BHAF. Had about 75 in mine. Make sure you don't have any leaks in your welds and clean the inside very well. If you want some pics PM me your e-mail. I'm sure it's not for everyone but it might help someone.
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Postby sdstriper » Thu Jan 11, 2007 3:02 am

If you buy a piece of pipe or tube with a longer tangent length than they normally come in, you can get your tube without welding 101. I bought 45* angle mandrel bent aluminum with 18" tangent lengths, then cut down both ends to get the fit I desired. It fits into my BHAF (no rubber fitting there) and has a rubber 45 with reducer (early H1C) at the turbo. Three T-bolt clamps. Around $75 If I remember correctly.
1989 D250, 727, 3.07, BHAF, 4" exhaust, Usual Suspect Gauges, tuned VE, OSPP
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Postby RumbleFish » Thu Jan 11, 2007 1:26 pm

sdstriper wrote:If you buy a piece of pipe or tube with a longer tangent length than they normally come in, you can get your tube without welding 101. I bought 45* angle mandrel bent aluminum with 18" tangent lengths, then cut down both ends to get the fit I desired. It fits into my BHAF (no rubber fitting there) and has a rubber 45 with reducer (early H1C) at the turbo. Three T-bolt clamps. Around $75 If I remember correctly.


Where in the heck did you find a rubber 45? I've got a 3" (early H1C as well) aluminum 45, but I cannot for the life of me find a rubber 45 to go on the turbo. Enquiring minds want to know.....
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Postby BC847 » Thu Jan 11, 2007 3:38 pm

RumbleFish wrote:Where in the heck did you find a rubber 45? I've got a 3" (early H1C as well) aluminum 45, but I cannot for the life of me find a rubber 45 to go on the turbo. Enquiring minds want to know.....


Rubber Hoses And Clamps (Link) :)
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Postby sdstriper » Thu Jan 11, 2007 5:22 pm

Rubber 4" 45*, http://store.airflo.com/45hl4.html and you'll need one of these too, http://store.airflo.com/7-423.html

On the tubing I bought 18" on each side of the bend because I wanted plenty of material so I could cut it down to where I wanted, I ended up cutting it nearly to the 45* on the one side. You can get by with 12" on each side of the bend if you are using the BHAF that is 12" long. I trimmed the lip on the ID of my BHAF so the tubing fits in there a few inches, tight fit too. I wanted the tube further in there so it doesn't pop off the thing, it makes for better clamping. Same with the other end, I have the tube inside the rubber 45* approx. 3 inches. It isn't coming apart I guarantee it.

T-Bolt clamps I got at McMaster-Carr online. 4 9/32 to 4 9/16 range, 3/4 width.
1989 D250, 727, 3.07, BHAF, 4" exhaust, Usual Suspect Gauges, tuned VE, OSPP
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Postby Greenleaf » Fri Jan 12, 2007 3:42 am

Guys,

Do what you like, but the intake for a Bluebird bus TC 2000 w/Cummins 5.9 is what you need. End of story.
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Postby g1625s » Fri Jan 12, 2007 5:08 am

Greenleaf wrote:Guys,

Do what you like, but the intake for a Bluebird bus TC 2000 w/Cummins 5.9 is what you need. End of story.


Pics? Sources? You've got my attention:)
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Postby 92 D/UNIT » Fri Jan 12, 2007 8:11 am

ya greanleaf show us some pics.
Brian 92 D 250 250K, A518, pump mods, BHAF, 4X15s, 4" turbo back dual exh, 3200 spring, HTB2 62/12.

SOLD 92 w250 ex cab, 5 spd, 3.54, 320,000, WH1E 14, Fuel pin, pods,shortened 4200 gs, Bhaf, 4" turbo back
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Postby Greenleaf » Fri Jan 12, 2007 10:24 am

I have problems posting up pictures on this web site. Bedsides, you know what it looks like. just as you have described:

*4" rubber 45° held to turbo w/spring loaded (T Bolt) clamp.
*45° Exhaust pipe held to 45° rubber w/spring loaded (T Bolt)clamp.
*Another spring loaded (T Bolt) clamp to secure what-ever-filter you use to the
exhaust pipe.
*A Nelson exhaust pipe "hanger" to support the end of said pipe. The bus dosn't use a support because it attatches to the frame mounted air filter box. The hanger is rubber shock mounted and the strp end is bent to 90° and bolter to the bottom of the inner fender.
*A 5" hose clamp worm drive to secure the exhaust pipe to the "hanger

I have been substituing a NELSON exhaust pipe for the bluebird pipe, cuz BB wan'ts like 35.00 for the pipe and a truck dealer only asks like $17.00

My total cost is under $60.00

The Nelson pipe # is 89084A ($15.70) 12 " long legs ( each end from the center)
Hanger # is Nelson 89519K

The pipe is a bit long at the filter end and I cut off 3.5" for **MY*** filter. A different filter may require more or less. I have a shorter pipe at one time, but I didn't like it as I thought it was a bit too short. Nelson # 89782A ($14.85)

One could also build a shield as some have, and incorporate the end of the pipe into the shield to serve as the support.

I know some guys choose not to support the filter and allow it to bounce around inside the inner fender well. That's ok to, I suppose. :oops:

When I service the OIL filter, I remove the clamp from the turbo and the worm drive hose clamp from the exhaust pipe hanger.
1990/1992 D250 Ram Diesels Modified by *Smokehouse Diesel* Ashland, Ohio ( )==='==~

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Postby PToombs » Sat Jan 13, 2007 3:24 pm

What I would like is one of those Old Smokey BHAF mounts. Any body got one they don't need :?:
pete

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Postby 92 D/UNIT » Sat Jan 13, 2007 5:26 pm

just have a sheet metal make you one i dont think it would cost much. heres a link with the measurements
http://www.dieseltruckresource.com/pics ... cat=500%22
Brian 92 D 250 250K, A518, pump mods, BHAF, 4X15s, 4" turbo back dual exh, 3200 spring, HTB2 62/12.

SOLD 92 w250 ex cab, 5 spd, 3.54, 320,000, WH1E 14, Fuel pin, pods,shortened 4200 gs, Bhaf, 4" turbo back
388/886
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Postby PToombs » Sun Jan 14, 2007 4:50 pm

Hey that is awesome. Thanks D/unit.
I like this site better everytime I'm on here! :)
It pays to have guys from different sites!
pete

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Postby g1625s » Mon Jan 15, 2007 5:53 pm

Here's my airflo.com setup. I just love threads with pics--it hurts my brain less than reading!


Image
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Postby Falcon » Tue Jan 16, 2007 10:53 am

Here is mine

Image
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93 ex cab 4x4, Hybred 35/40,4" exaust all the way,pump turned alittle,DDP Stage III's, 366 spring,DDP fuel pin,AFE first gen air intake,pyro and boost gauges
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Postby 12valve350 » Tue Aug 25, 2009 1:32 am

heres my homade intake[imgImage[/img]
Six in a row makes 'er go, Eight in a v, theres nothin' too see!
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